Wind turbine blade with improved glue joints and related method

Abstract

The disclosure presents a wind turbine blade and a method of manufacturing a wind turbine blade, wherein the wind turbine blade is manufactured as a composite structure comprising a reinforcement material embedded in a polymer matrix, the method comprising: providing a first blade mould with a first blade shell part having a leading edge, a trailing edge, and a first leading edge glue surface at the leading edge, the first blade mould comprising a first leading edge flange; providing a second blade mould with a second blade shell part having a leading edge, a trailing edge, and a second leading edge glue surface at the leading edge, the second blade mould comprising a second leading edge flange; applying glue to a leading edge glue surface; providing one or more leading edge spacer elements at a leading edge flange; arranging the second blade mould on the first blade mould, such that the one or more leading edge spacer elements are arranged between the first leading edge flange and the second leading edge flange; applying a pressure to the second blade shell part; and curing the glue.

The invention claimed is: 
     
       1. A method of manufacturing a wind turbine blade ( 10 ), wherein the wind turbine blade is manufactured as a composite structure comprising a reinforcement material embedded in a polymer matrix, the method comprising:
 providing a first blade mould ( 70 ) with a first blade shell part ( 72 ) having a leading edge ( 74 ), a trailing edge, and a first leading edge glue surface ( 76 ) at the leading edge ( 74 ), the first blade mould ( 70 ) comprising a first leading edge flange ( 80 ); 
 providing a second blade mould ( 82 ) with a second blade shell part ( 84 ) having a leading edge ( 86 ), a trailing edge, and a second leading edge glue surface ( 87 ) at the leading edge ( 86 ), the second blade mould ( 82 ) comprising a second leading edge flange ( 89 ); 
 applying glue ( 90 ) to at least one of the first and second leading edge glue surfaces ( 76 ;  87 ); 
 providing one or more leading edge spacer elements ( 92 ) at least one of the first and second leading edge flanges ( 80 ;  89 ); 
 arranging the second blade mould ( 82 ) on the first blade mould ( 70 ), such that the one or more leading edge spacer elements ( 92 ) are arranged between the first leading edge flange ( 80 ) and the second leading edge flange ( 89 ); 
 applying a pressure to the second blade shell part ( 84 ); and 
 curing the glue ( 90 ). 
 
     
     
       2. The method according to  claim 1 , wherein the one or more leading edge spacer elements ( 92 ) have a thickness in the range from 1 mm to 10 mm. 
     
     
       3. The method according to  claim 1 , wherein the method comprises aligning the leading edges ( 74 ;  86 ) of the first blade shell part ( 72 ) and the second blade shell part ( 84 ) prior to applying the pressure to the second blade shell part ( 84 ). 
     
     
       4. The method according to  claim 1 , wherein the method comprises:
 arranging a primary web ( 102 ) on the first blade shell part ( 72 ), wherein arranging a primary web ( 102 ) on the first blade shell part ( 72 ) comprises arranging one or more first primary spacer elements ( 110 ) between a first glue surface of the primary web ( 102 ) and a primary glue surface of the first blade shell part ( 72 ), and applying glue between the first glue surface of the primary web ( 102 ) and the primary glue surface of the first blade shell part ( 72 ). 
 
     
     
       5. The method according to  claim 4 , wherein the one or more first primary spacer elements ( 110 ) have a thickness in the range from 1 to 10 mm. 
     
     
       6. The method according to  claim 4 , wherein the method comprises:
 arranging one or more second primary spacer elements ( 122 ) between a second glue surface of the primary web ( 102 ) and a primary glue surface of the second blade shell part ( 84 ); and 
 applying glue ( 122 ) between the second glue surface of the primary web and the primary glue surface of the second blade shell part ( 84 ). 
 
     
     
       7. The method according to  claim 6 , wherein the one or more second primary spacer elements ( 122 ) have a thickness in the range from 1 to 10 mm. 
     
     
       8. The method according to  claim 1 , wherein the method comprises:
 providing one or more trailing edge spacer elements at a first trailing edge flange of the first blade mould ( 70 ) or a second trailing edge flange of the second blade mould ( 82 ); and 
 arranging the second blade mould ( 82 ) on the first blade mould ( 70 ), such that the one or more trailing edge spacer elements are arranged between the first trailing edge flange and the second trailing edge flange. 
 
     
     
       9. The method according to  claim 1 , wherein the step of applying the pressure to the second blade shell part ( 84 ) comprises applying a negative pressure to an inside of the wind turbine blade ( 10 ). 
     
     
       10. The method according to  claim 1 , wherein the step of applying the pressure to the second blade shell part ( 84 ) comprises applying a positive pressure to an outer surface of second blade shell part ( 84 ).